This study was conducted to evaluate the feasibility of applying a bending process as an alternative to the conventional welding method for rolled homogeneous armor(RHA) steel used in the turret structures of tanks. After analyzing the turret geometry and the mechanical characteristics of RHA steel, the upper and lower die profiles were optimized based on the MIL-DTL-12560 specification. Through forming simulations, the appropriate die opening width and punch stroke were derived. In particular, the final bending conditions were determined by accounting for springback effects. Structural analysis results confirmed that the maximum residual stress and total strain remained within the allowable mechanical limits of RHA steel, and the strain values approached the material’s elongation limit of approximately 15%, ensuring practical forming stability. This study presents a practical guideline for die design and bending conditions applicable to high-strength armor steels, and is expected to serve as a foundational reference for process optimization in the manufacturing of military vehicles and protective structures.

The K2 tank not only has excellent mobility but also has excellent protection performance. Armor steel is used to provide structural protection, and the turret structure is made of rolled homogeneous armor (RHA) plates. Most processes for fabricating structures involve welding, but RHA steel has the problem of being susceptible to thermal deformation. To compensate for this, a plan to apply the bending method was considered. In this study, prior to applying the bending method to an actual vehicle, mechanical property evaluations were performed on materials, welding, and bending specimens. It has been proven that the bending method can achieve performance equivalent to or better than the welding method. The verification tests included hardness tests, tensile tests, fatigue tests, and impact tests. All tests except the impact test confirmed that the bending method was superior to the welding method. In the case of the impact test, the impact value of the bending method was lower, but it satisfied the standard with a value higher than the minimum requirement according to the standard, so it is judged that there will be no problem in applying the bending method.